Recycled fabric structure, knitted vamp cloth and method of manufacturing yarn

ABSTRACT

A recycled fabric structure is provided, which includes a plurality of types of blended yarn arranged by weaving or interlacing. Wherein, each of the types of the blended yarn has a plurality of first fibers and a plurality of second fibers vertically arranged and interloped with each other. The plurality of first fibers accounts for 30% to 50% of the total weight of the blended yarn. The first fiber is a recycled fiber.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from Taiwan Patent Application No. 106205803, filed on Apr. 25, 2017 at Taiwan Intellectual Property Office, the contents of which are hereby incorporated by reference in their entirety for all purposes.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present application is related to a fabric structure, in particular, a recycled fabric, a knitted vamp cloth and a method of manufacturing yarn.

2. Description of the Related Art

Daily life presents new challenges, and to face those challenges, new products are constantly being developed. The textile industry, and those industries related thereto have provided new products to face such challenges. The advancing developments continue to evolve over time, each step improving daily quality of life.

It is typical to cut a textile from a textile roll into a demanded size for use in a product. The remaining material may be unsuitable for many applications, and will likely be discarded. In today's environmentally friendly world, it is critical to recycle waste when possible, in order to reduce environmental pollution. As the trend of environmental awareness continues to grow, efficient use of resources, and methods of recycling or reusing materials are topics of concern.

Fancy yarn is a type of yarn which is identified by having special color distributions, sizes and wire diameters. In order to provide the yarn a variability of wire diameter differences, a two-ply yarn is often manufactured by plying, twinning, false twisting, adding additional neps and twisting in a cotton mixing process, or applying an air-jet texture process to a filament tow. To further improve the complexity (such as color) of the fancy yarn, a process of adjusting the spinning, dyeing process, or adding a variety of additives in raw materials is required, which increases the cost so that the yarn cannot be simply made.

In summary, the inventor of the present application designs a recycled fabric structure, a knitted vamp cloth and the method of manufacturing the same are provided after years of painstaking research, which improve the defects presented in the prior art and will further improve the practical implementation in industries.

SUMMARY OF THE INVENTION

According to the problems mentioned above, the subject of the present application is to provide a recycled fabric structure, a knitted vamp cloth and the manufacturing method thereof, and utilizing these materials and this method, to become able to significantly reduce environmental pollution and achieve an efficient use of the resources.

Based on the above subjects, the present invention provides a recycled fabric structure, which comprises: a plurality of types of blended yarn arranged by weaving or interlacing, wherein each of the types of blended yarn has a plurality of first fibers and a plurality of second fibers vertically arranged and twisted with each other; the first fibers accounts for 30% to 50% of a total weight of the blended yarn; the first fiber is a recycled fiber generated by a machinery fiber opening process applied to a recycled knitted cloth; the blended yarn is a one-ply yarn and has a random wire diameter and a color difference; and a slub part of the one-ply yarn is formed by a part of the plurality of first fibers.

Preferably, the part of the plurality of first fibers comprises a nep.

Preferably, the nep of each of the plurality of first fibers has a random size, and forms the slub part of the one-ply yarn.

Preferably, the recycled knitted cloth comprises a knitted vamp cloth dyed with at least two colors.

Preferably, a slub of the plurality of first fibers has a random color.

Preferably, the lengths of the plurality of first fibers and the plurality of second fibers are from 30 to 40 mm.

Preferably, the plurality of first fibers comprises at least one type of yarn forming the recycled knitted cloth, and the type of yarn forming the recycled knitted cloth has a denier value from 75D to 600D and a polyfilament yarn number from 24 f to 72 f.

Preferably, a fiber elongation of the blended yarn is a value from 10% to 25%.

Preferably, a fiber strength of the blended yarn is from 20 to 40 cN/tex.

Preferably, a denier value of the blended yarn is from 150D to 600D.

Preferably, the thread count of the blended yarn is from 6 s to 20 s.

Preferably, the recycled fiber comprises one of cotton, polyester, polyamide or rayon, or a combination thereof.

Based on the above subjects, the present invention provides a knitted vamp cloth, which comprises the aforementioned recycled fabric structure.

Based on the above subjects, the present invention provides a method of manufacturing a yarn, comprising steps as follows: cutting a knitted cloth into a predetermined size; applying an machinery fiber opening process to the cut knitted cloth to form a plurality of first fibers having a predetermined length, wherein a part of the plurality of first fibers comprises a nep; mixing the plurality of first fibers and the plurality of second fibers to form an evenly mixed cotton layer; and apply a cotton carding process and a doubling process to the mixed cotton layer, and applying a ring-spinning process to form an one-ply yarn; wherein, the one-ply yarn has a random wire diameter and a color difference, the plurality of first fibers accounts for 30% to 50% of the total weight of the blended yarn, a nep of the plurality of first fibers has a random size, and a part of the plurality of first fibers forms a slub part of the one-ply yarn.

Preferably, the knitted cloth is a knitted vamp cloth dyed with at least two colors.

Preferably, the lengths of the plurality of first fibers and the plurality of second fibers are from 30 to 40 mm.

Preferably, the slub of the plurality of first fibers has a random color.

Preferably, a denier value of the one-ply yarn is in a range from 150D to 600D.

Preferably, the thread count of the one-ply yarn is 6 s to 20 s.

Preferably, the plurality of first fibers comprises at least one type of yarn forming the recycled knitted cloth, and the type of yarn forming the recycled knitted cloth has a denier value from 75D to 600D and a polyfilament yarn number from 24 f to 72 f.

According to the above descriptions, the recycled fabric structure, the knitted vamp cloth and the method of manufacturing the same may have one or more following advantages:

(1) Capability to be spun by a short fiber and manufacture an one-ply yarn having randomly distributed wire diameters. Since the yarn is one-ply yarn, it is able to control and make the product yarn still have special patterns when the wire diameter is relatively small.

(2) The opened knitted cloth generates neps easily. During the spinning process, fibers containing neps may generate slubs, and therefore form different wire diameters. The product yarn may be generated without depending on the means of plying or adding neps.

(3) The present application may form types of yarn which are natural and have irregular colors, and which may be generated by reconstituting the remaining material consisting of knitted cloth. In particular, the present application details recycling of the remaining dyed knitted cloth materials which have various colors, and possess special color distributions and pattern differences without dying the yarn.

BRIEF DESCRIPTION OF THE DOUBLINGS

FIG. 1 is a schematic diagram of the recycled fabric structure of the first preferable embodiment of the present application.

FIG. 2 is a schematic diagram of a blended yarn illustrated in FIG. 1.

FIG. 3 is a schematic diagram of a blended yarn illustrated in FIG. 1.

FIG. 4 is a schematic diagram of a blended yarn illustrated in FIG. 1.

FIG. 5 is a schematic diagram of a blended yarn illustrated in FIG. 1.

FIGS. 6A and 6B are flow charts of a manufacturing process of the recycled fabric structure of the first preferable embodiment of the present application.

FIGS. 7A and 7B are schematic diagrams of the second preferable embodiment of the present application.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, the embodiments of the recycled fabric structure 1 of the present application will be explained taken in conjunction with the appending drawings. For ease of understanding, the same elements are labeled by the same numerals in following embodiments.

Please refer to FIGS. 1 to 5, which are schematic diagrams of the recycled fabric structure 1 of the first preferable embodiment of the present application. In the doublings, the recycled fabric structure 1 comprises a plurality of blended yarn 10 arranged by weaving or interlacing. Wherein, each of the blended yarn 10 has a plurality of cotton bars 12 vertically arranged and intertwined with each other, and is arranged in a bar shape. The plurality of cotton bars 12 have a plurality of first fibers 14 and a plurality of second fibers 16 which are mixed evenly. Wherein, the first fibers 14 are recycled fibers generated by a machinery fiber opening process applied to a recycled knitted cloth. The first fibers 14 account for 30%, 35%, 40%, 45% or 50% of the total weight of the blended yarn. Wherein the blended yarn 10 is a one-ply yarn and has a random wire diameter and a color difference. Whereas a part of the plurality of first fibers 14 forms the slub 13 part of the one-ply yarn. That is, a part of the plurality of first fibers 14 comprises a nep which has a random size, and forms the slub 13 part of the one-ply yarn. In the present embodiment, the blended yarn 10 is formed into loops, thereby the loops are interlooped to each other and a knit is formed. The texture is soft, with good wrinkle resistance, breathability, and greater extensibility and flexibility.

Please refer to FIGS. 5, as well as 6A and 6B, the method of manufacturing the recycled fabric structure 1 of the first preferable embodiment of the present application will be described, comprising the steps as follows:

Step 100: Recycling knitted cloth waste, and cutting the knitted cloth waste into a size between 3 cm and 5 cm. The way of cutting is two-paths cutting, which is beneficial to a subsequent fiber opening process for forming spinable fiber. First, the knitted cloth waste is applied with a vertical cutting 601 and becomes bar shaped, then is applied with a horizontal cutting 602 and becomes block shaped, as shown in FIG. 6B. The cutting size and method is not limited thereto and may be adjusted depending on cloth types. The knitted cloth waste may comprise cotton, polyester, polyamide or rayon. Wherein, the source of the knitted cloth waste may be any type of remaining cloth material. Specifically, the recycled knitted cloth waste of the present application may be dyed knitted vamp cloth, for instance, the cloth being dyed, printed or digitally printed by at least two colors may be recycled, or the dyed knitted cloth obtained from different sources may be mixed. Hence, a final product of the yarn does not need to be applied with a dye process, and still possesses natural, irregular colors.

Step 200: Fiber opening and cotton scotching; applying machinery fiber opening, blending, opening and cleaning to the cut knitted cloth waste by a needle-punch wheel so as to obtain an even cotton layer. With special attention to FIG. 5, blending is a process that mixes various types of fibers evenly, that is, mixing a first fiber 14 and a second fiber 16 (e.g. artificial fiber) which belong to different types but have similar qualities, and form a mixed cotton layer. The opening and cleaning are processes that release the fiber of the mixed cotton layer so that the mixed fibers having block shape or bundle shape transform from a large shape to a small shape, and impurities are removed. In addition, the opening and cleaning may be performed by selection of the combinations between different types of machines and beater depending on the type and level of the fiber and the impurities contained therein. In particular, the routine of the fiber opening process of the present application maybe performed one time, two times, three times, mostly five times, six times or seven times of multiple fiber opening. The attrition rate of the fiber opening process applied to the knitted cloth waste may be lower than 30%, in some circumstances preferably 20% or in other circumstances preferably 10%, and the length and the spinnability of the opened fiber may be improved, by sustaining the routine of the fiber opening process and reducing the tearing force during each procedure of the fiber opening processes, or gradually increasing the tearing force during the fiber opening process. Further, the fiber opening process may control the fiber length after the process, and for instance, may obtain a demanded fiber length by controlling the processes of feeding, tearing and cutting. Preferably, the fiber length is in the range of 30 mm to 40 mm, for instance, and may be about 30 mm, 32 mm, 34 mm, 36 mm, 38 mm or 40 mm. For example, the purpose of controlling the fiber length thereof may be achieved by stably feeding the fiber through a conveyor wheel having high gripping force. During the process of fiber opening process applied to the knitted cloth, since knitted cloth is the fabric formed by the yarn interlooped and knitted to each other, the friction generated during tearing may form a fiber which has neps (fiber fast knot). However, the spinnability of the fiber having neps still may be improved by controlling the fiber length within predetermined ranges, for instance, controlling the length so that each of the fibers has one or mostly two neps thereon.

Step 300: Carding; carding the cotton roll or cotton layer and arranging it accordingly, then simultaneously and repeatedly removing impurities and fluff, keeping spinnable fiber, mixing fibers and manufacturing cotton nets, improving the evenness thereof and condensing the previous mentioned fibers into a demanded cotton bar 12 which is also called a sleeve, in order to be beneficial to subsequent processes.

Step 400: Doubling; doubling 6 to 8 of the cotton bars 12 (here means the sleeves) and drafting, in order to manufacture drawn sleeves. This process straightens the mixed fibers and arranges them in parallel with each other, doubles the drawn sleeves having uneven thicknesses together and spins into the drawn sleeves having even thicknesses. Further, this step removes the remaining fluff and impurities. The structure is shown in FIGS. 3 and 4.

Step 500: Modeling; drafting and extending the cotton bars 12 (here means the sleeves) by an alternating process and a yarn ring-spinning process, in order to make the fiber straighter and more parallel. Further, the cotton bar 12 should have an appropriate diameter so that the volume may be reduced. Subsequently, a twisting process is performed so that a demanded thinness and twistedness may be achieved and a blended yarn 10 having strength may be produced. Then, winding the blended yarn 10 on a bobbin and modeling to a specific size and shape, as shown in FIG. 2. Wherein, the fiber elongation of the blended yarn 10 is 10% to 25%, the fiber strength of the blended yarn is from 20 to 40 cN/tex, and the denier value of the blended yarn is from 150D to 600D.

Step 600: Weaving yarn; a recycled fabric structure 1 of the present application may be manufactured by weaving or interlooping the blended yarn 10 though textile techniques, and further be utilized in various textiles such as clothing, vamps, gloves, hats, purses and accessories.

Practically, the remaining material are collected as knitted cloth waste, and the knitted cloth waste are cut into a predetermined size. The cut knitted cloth waste are then applied with a fiber opening process and cotton scutching. The knitted cloth wastes are applied with the fiber opening process several times in order to improve fluffiness. The first fiber 14 and the second fiber 16 are then mixed sufficiently and evenly to produce even cotton rolls or cotton layers. A cotton carding process is then performed, in which the cotton rolls or the cotton layers are carded, impurities removed, and mixed in order to produce even cotton bars 12. Subsequently, the plurality of cotton bars 12 are doubled and drafted, and vertically arranged and twisted with each other in order to produce even cotton bars 12. Finally, an alternating process and a yarn ring-spinning process are performed to produce a blended yarn 10 having an appropriated diameter and strength. The product blended yarn 10 may be wound on a bobbin for ease of storage. Weaving or interlooping the produced blended yarn 10 mentioned above, will produce a recycled fabric structure of the present application.

Specifically, a knitted cloth waste being dyed may be recycled. The yarn of such type of knitted cloth has a denier value of 75D, 150D, 300D or 600D, or a polyfilament yarn number of 24 f, 48 f or 72 f. The recycled fibers having different specification mentioned above may be mixed and produce a yarn having a wire diameter difference. For instance, the thread count of the blended yarn forming the blended yarn is 6 s, 7 s, 8 s, 10 s, 11 s, 12 s, 15 s, or 20 s. Hence, the reason of the slub 13 formed on the blended yarn 10 of the present application may comprises at least one of the followings: (1) the slubs covering the recycled fiber during twisting; (2) the wire diameter difference generated by intercrossing of different specifications of fibers during mixing recycled knitted clothes. The blended yarn 10 of the recycled fabric structure 1 of the present application have such the same physical properties as a blended yarn 10 of a normal fabric that it is appropriate for manufacturing knitted vamp clothes. For instance, when the blended yarn has a denier value between 150D to 600D, the fiber strength of the blended yarn 10 of a normal fabric is from 20 to 40 cN/tex, and the elongation is 10% to 25%. The blended yarn 10 of the recycled fabric structure 1 of the present application is also within the above range.

Please refer to FIGS. 7A and 7B, the main structure of the recycled fabric structure 2 of the second preferable embodiment of the present application is mostly the same as that of the aforementioned first embodiment. The differences between the present embodiment and the first embodiment are: the woven fabric is constructed by perpendicularly interlacing two or more groups of the vertical blended yarn 10 and the horizontal blended yarn 10 is relatively solid and stable, and has varieties of arrangement by various patterns.

In summary, the recycled fabric structure 1 of the present application recycles and utilizes knitted cloth waste which is already dyed. Hence, natural, irregular colors are reused without the requirement of an additional dye process. This may significantly reduce environmental pollution and achieve high efficiency for recycling and reusing of the resources, without affecting the properties of the recycled fabric.

The above descriptions are only exemplary, and should not be considered as limitations. It is able to make equivalent modifications and improvement without departing from the concept of the present disclosure, and these all belong to the appending claims of the present disclosure. 

What is claimed is:
 1. A recycled fabric structure, comprising: a plurality of types of blended yarn arranged by weaving or knitting, wherein each of the types of blended yarn has a plurality of first fibers and a plurality of second fibers vertically arranged and interlooped with each other; the plurality of first fibers accounts for 30% to 50% of a total weight of the blended yarn; the plurality of first fiber is a recycled fiber generated by a machinery fiber opening process applied to a recycled knitted cloth; the blended yarn is an one-ply yarn and has a random wire diameter and a color difference; and a slub part of the one-ply yarn is formed by a part of the plurality of first fibers.
 2. The recycled fabric structure of claim 1, wherein the part of the plurality of first fibers comprises a nep.
 3. The recycled fabric structure of claim 2, wherein the nep of each of the plurality of first fibers has a random size and forms the slub part of the one-ply yarn.
 4. The recycled fabric structure of claim 1, wherein the recycled knitted cloth comprises a knitted vamp cloth dyed with at least two colors.
 5. The recycled fabric structure of claim 1, wherein the slub of the plurality of first fibers has a random color.
 6. The recycled fabric structure of claim 1, wherein the lengths of the plurality of first fibers and the plurality of second fibers are from 30 to 40 mm.
 7. The recycled fabric structure of claim 1, wherein the plurality of first fibers comprises at least one type of yarn forming the recycled knitted cloth, and the type of yarn forming the recycled knitted cloth has a denier value from 75D to 600D and a polyfilament yarn number from 24 f to 72 f.
 8. The recycled fabric structure of claim 1, wherein a fiber elongation of the blended yarn is a value from 10% to 25%.
 9. The recycled fabric structure of claim 1, wherein a fiber strength of the blended yarn is from 20 to 40 cN/tex.
 10. The recycled fabric structure of claim 1, wherein a denier value of the blended yarn is from 150D to 600D.
 11. The recycled fabric structure of claim 1, wherein a thread count of the blended yarn is from 6 s to 20 s.
 12. The recycled fabric structure of claim 1, wherein the recycled fiber comprises one of cotton, polyester, polyamide or rayon, or a combination thereof.
 13. A knitted vamp cloth, comprising the recycled fabric structure of claim
 1. 14. A method of manufacturing yarn, comprising steps as follows: cutting a knitted cloth into a predetermined size; applying an machinery fiber opening process to the cut knitted cloth to form a plurality of first fibers having a predetermined length, wherein a part of the plurality of first fibers comprises a nep; mixing the plurality of first fibers and the plurality of second fibers to form a evenly mixed cotton layer; and applying a cotton carding process and a doubling process to the mixed cotton layer, and applying a ring-spinning process to form an one-ply yarn; wherein, the one-ply yarn has a random wire diameter and a color difference, the plurality of first fibers accounts for 30% to 50% of a total weight of the one-ply yarn, the nep of the plurality of first fibers has a random size, and a part of the plurality of first fibers forms a slub part of the one-ply yarn.
 15. The method of claim 14, wherein the knitted cloth is a knitted vamp cloth dyed with at least two colors.
 16. The method of claim 14, wherein the lengths of the plurality of first fibers and the plurality of second fibers are from 30 to 40 mm.
 17. The method of claim 15, wherein a slub of the plurality of first fibers has a random color.
 18. The method of claim 14, wherein a denier value of the one-ply yarn is in a range from 150D to 600D.
 19. The method of claim 14, wherein a thread count of the one-ply yarn is from 6 s to 20 s.
 20. The method of claim 14, wherein the plurality of first fibers comprises at least one type of yarn forming the recycled knitted cloth, and the type of yarn forming the recycled knitted cloth has a denier value from 75D to 600D and a polyfilament yarn number from 24 f to 72 f. 